Orthopaedic brace having a range of motion hinge with an adjustable-length strut

ABSTRACT

Abstract of the Disclosure 
     An orthopaedic brace includes a strut length adjustment assembly to change the operable length of the strut for sizing the brace on a patient without the need for special tools or cutting of the strut.  The adjustment assembly includes a biased adjustment mechanism that coacts with a plurality of notches in the strut to variably set/position the strut relative to the adjustment assembly to set the struts length.  Each upper and lower strut preferably includes a strut length adjustment assembly to independently set the length of each strut.  The strut length adjustment assembly retains a strut and includes a strap retention mechanism that is configured to releasably engage the strap.

Detailed Description of the Invention Related Applications

The present application is a continuation of application Serial No.09/608,940, filed on June 30, 2000, now Patent No. 6,383,156, issued May7, 2002, which claims priority to provisional application Serial No.60/156,342, filed on September 27, 1999. The complete disclosures ofthese applications are hereby expressly incorporated by reference.

Field of the Invention

The present application relates to orthopaedic braces adapted with anadjustable-length strut for use in stabilizing a joint after invasivesurgery.

Description of the Related Art

In order to ensure the proper healing of a human joint after an injuryor invasive surgery, it is often desirable to limit the pivotal motionof the human joint to a predetermined angular range between fullextension and full flexion. The pivotal motion may be limited by a rangeof motion hinge disposed between an upper strut and a lower strut. Inorder for the orthopaedic brace to function properly, the struts must beadaptable to the body proportions of the patient.

The following U.S. Patents, which describe orthopaedic braces of thisgeneral type, are herein incorporated by reference to establish thenature of such range of motion braces, and how and why such equipment isused. U.S. Patent No. 552,143 issued on December 31, 1895; U.S. PatentNo. 649,237 issued on May 8, 1900; U.S. Patent No. 4,776,326 issued toYoung et al., on October 11, 1988 entitled “Modular Lower Limb BracingSystem”; U.S. Patent No. 4,817,588 issued to Bledsoe on April 4, 1989entitled “Motion Restraining Knee Brace”; U.S. Patent No. 4,982,732issued to Morris on January 8, 1991 entitled “Orthopedic RehabilitationKnee Brace”; U.S. Patent No. 5,052,379 issued to Airy et al., on October1, 1991 entitled “Combination Brace and Wearable Exercise Apparatus forBody Joints”; and U.S. Patent No. 5,018,514 issued to Grood et al., onMay 28, 1991 entitled “Knee Brace”.

It is well known that the orthopaedic braces described in theaforementioned incorporated patents suffer various problems,shortcomings and disadvantages. In some cases such braces cannot beadjusted to fit the patient, rather, the braces come in various fixedsizes. Alternatively, the braces are not easily adjustable, requiring,for example, tools to change the size of the struts. Some braces requireactual cutting or breaking off pieces of the struts to permanentlychange the length of the struts. Others rely upon friction, as from atightening screw, to less than positively lock the strut at the desirelength.

It is thus an object of the present invention to provide an orthopaedicbrace that is easy to adjust.

It is thus another object of the present invention to provide anorthopaedic brace that is adjustable without a need for tools.

It is thus further an object of the present invention to provide anorthopaedic brace that is adjustable without cutting or breaking astrut.

Summary of the Invention

The present invention is an orthopaedic brace that has adjustable lengthstruts.

In one form, the present invention is an orthopaedic brace including afirst strut, a second strut, a hinge disposed between the first andsecond struts, and an adjustment assembly disposed on one of the firstand second struts. The hinge is configured to allow movement of one ofthe first and second struts about an axis defined by the hinge. Theadjustment assembly is configured to cooperate with the one of the firstand second struts to adjustably set an operative length of the one ofthe first and second struts.

In another form, the present invention is an orthopaedic brace includingan upper strut, a lower strut, a hinge disposed between the upper strutand the lower strut, and an adjustment assembly disposed on one of thefirst and second struts. The hinge is configured to allow movement ofone of the upper and lower struts about an axis defined by the hinge.One of the upper and lower struts has a plurality of notches defining aplurality of strut length settings. The adjustment assembly isconfigured to cooperate with any one of the plurality of notches of theone of the first and second struts to selectively set a length of theone of the first and second struts.

In yet another form, the present invention is an orthopaedic braceincluding an upper strut, a lower strut, a hinge disposed between theupper strut and the lower strut, an upper adjustment assembly disposedon the upper strut, and a lower adjustment assembly disposed on thelower strut. The hinge is configured to allow movement of one of theupper and lower struts about an axis defined by the hinge. The upperadjustment assembly is configured to cooperate with the upper strut toadjustably set a length of the upper strut. The lower adjustmentassembly is configured to cooperate with the lower strut to adjustablyset a length of the lower strut.

Accordingly, the present invention improves upon the prior art byproviding an orthopaedic brace strut that may be changed in lengthwithout the use of tools and with the ability to return to the originallength, or some other length as desired.

The present invention also provides for a single-action positive lockfor a strut length adjustment assembly rather than relying on friction.The ability to size and resize the struts provides a cost-effective andcomfortable means to apply an orthopaedic brace to virtually any jointon the human body and eliminates the need to carry large inventories ofbraces that cannot be sized. By providing a positive lock, the improvedbrace also better protects the patient and speeds recovery.

The present invention also allows contoured wings, with cushioningmaterial and/or non-slip material attached, to be used to limit movementof the brace after it has been attached and to provide increased comfortto the patient.

Brief Description of the Drawings

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention will be better understood by reference to the followingdescription of embodiments of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is a side perspective view of an adjustable orthopaedic braceassembly having adjustable-length strut assemblies that embodiesprinciples of the present invention showing the brace operativelyconnected to a human leg;

FIGS. 2A and 2B are, respectively, top and underside perspective viewsof an adjustable-length strut assembly for the orthopaedic brace of FIG.1;

FIG. 3 is an exploded, perspective view of the adjustable-length strutassembly of FIGS. 2A and 2B;

FIG. 4 is a cross-sectional view through the adjustable-length strutassembly taken along line 4-4 of FIG. 3;

FIG. 5 is a perspective view of a second embodiment of anadjustable-length strut assembly;

FIG. 6 is a cross-sectional view through the second embodiment of theadjustable-length strut assembly taken along line 6-6 of FIG. 5;

FIG. 7 is a cross-sectional view through the second embodiment of theadjustable-length strut assembly taken along line 7-7 of FIG. 6; and

FIG. 8 is a perspective view of a third embodiment of anadjustable-length strut assembly.

Corresponding reference characters indicate corresponding partsthroughout the several views.

Detailed Description of the Preferred Embodiment

An orthopaedic brace 10 is shown in Fig. 1 operatively attached to a leg64 using a plurality of straps 54 mounted on an upper strut 12 and alower strut 14 with a hinge assembly 16 disposed between the upper strut12 and the lower strut 14. While only one side of the orthopaedic brace10 is shown (i.e. the hinge assembly 16, the upper strut 12, and thelower strut 14 or “assembly”) it should be understood that an identical,but mirror image, assembly is provided on the opposite side of the leg64.

Each strut 12 and 14 is provided with a preferably identicallyconfigured wing assembly 18 although variations in either arecontemplated, which is slidably mounted for adjustable movement on theelongated struts 12 and 14. Stated in another manner, each strut 12 and14 is adjustable in length relative to the length of the strut betweenthe hinge 16 and the straps 54 through adjustable strut assemblies 18.Such will be considered hereafter as the length adjustment of a strut.It should be appreciated that such assemblies 18 may be provided on bothstruts 12 and 14, or only on one of the two struts 12 and 14. As well,it should also be appreciated that adjustability of the length of astrut may be considered as either or both the adjustment of the assembly18 relative to a strut (12 and/or 14), or as the adjustment of a strut(12 and/or 14) relative to the assembly 18.

The adjustable mounting of the wing assembly 18 on elongated struts 12and 14 allows the struts to telescope or move in and out, one inopposition to the other, of the respective wing assembly 18, as will bedescribed subsequently, to accommodate long or short legs, as oneexample, or long or short arms, as another example. Because thestructure and function of the wing assembly is similar regardless ofwhether mounted to the upper strut 12 or the lower strut 14, referencewill be made to only the upper strut 12 in the following description andits wing assembly 18. As well, because the structure and function of thestruts 12 and 14 are identical (assuming each strut terminates in a wingassembly 18), reference to strut 12 in the following description will beconstrued to pertain to strut 14.

Referring to Fig. 2A, the wing assembly 18 has a wing body 20, which ispreferably formed of a relatively rigid material, as for exampleplastic. The wing body 20 has an arcuate profile and is provided withone or more strap-retaining loops 22 for receiving the one or moreadjustable straps 54 that are threaded through the loops 22 to encircleboth the wing assembly 18 and a human limb, such as the leg 64 (asdepicted in Fig. 1), thereby immovably securing the brace 10 to the leg64, for example. Fig. 2B shows that the underside of the arcuate-shapedwing body 20 is provided with a generous layer of non-slip cushioning50, both to pad the wearer’s limb and to assure that the brace 10remains in place.

Figs. 2B, 3, 4A and 4B reveal that the underside of the wing body 20defines a unitary channel 46 that runs longitudinally down the entirelength the wing body 20. While the channel 46 is generally open,splitting the cushioning 50 into two halves, a lip 48 portion of thewing body 20 overhangs the channel 46 at each of the side edges of thechannel 46 down the entire longitudinal length of each side of thechannel 46. The channel 46 with opposing lips 48 receives the elongatedstrut 12 and retains and guides the strut 12 as it telescopes in and outof the channel 46. The open nature of the channel 46 also helps toreduce the overall weight of the orthopaedic brace 10.

Referring to Figs. 2B and 3, the strut 12 has formed through its body alongitudinal slot 60. The length of the slot 60 may be varied dependingupon the desired maximum and minimum lengths of the orthopaedic brace10. Longitudinally spaced down each side of the slot 60 are a pluralityof arcuate-shaped, stop notches generally designated 62. The notches 62are equally divided into a plurality of notches 62a that are mirrorimages of, and directly across the slot 60 from, a plurality of opposingnotches 62b, such that the opposing, arcuate-shaped pairs of notches 62aand 62b would define a circle if their ends were connected by an arc ofconstant radius equal to the distance from the center of the slot 60 tothe center of the opposing notches. One end of the slot 60 contains anarcuate-shaped notch 62c and the other end of the slot 60 contains amirror image arcuate-shaped notch 62d. Notches 62c and 62d are connectedon each end to the outer ends of notches 62a and 62b. It should beappreciated that the notches may be shaped other than that shown.

Referring to Fig. 3, it can be seen that the wing body 20 also defines adepression or chamber 28 on the top of the body 20 which is shown ascircular but can be any shape. The wing body 20 also defines an aperture26 of smaller diameter than the chamber 28 that extends through thecenter of the chamber 28 all the way to the slot 60 on the underside ofthe wing body 20. The chamber 28 and aperture 26 are adapted to house apositive-lock, adjustment or button assembly 30.

The adjustment assembly 30 (Fig. 3) has a generally flat pushbutton top32 that has a cylindrical extension 34 extending downward away from andperpendicular to the top. The cylindrical extension 34 has a radius thatallows it to freely travel through the aperture 26 and the slot 60without engaging any of the notches 62a and 62b. With additionalreference to Figs. 4a and 4b, a threaded aperture 36 extends downthrough the center of the top 32 and the extension 34 and is adapted toreceive a screw 42 from the underside of wing body 20. Fitting over theextension 34 is a biasing spring 38 of smaller diameter than the chamber26. A retaining bushing 40, with a radius approximating that of thenotches 62a, 62b, 62c and 62d, is secured to the adjustment assembly 30(extension 34) from the underside of the wing body 20 by the screw 42,which runs through the aperture 28 into the threaded aperture 36 in theextension 34 and thus the button 32. The spring 38 is thereby securedand sandwiched between the underside 33 of the top of the button 32 anda bottom 27 of the chamber 28.

Figs. 2B and 4A show the positively locked position of the adjustmentassembly 30. The spring 38 normally urges (biases) the push-button top32 up and away from the bottom of the chamber 27 and thereby captivelyurges the attached bushing 40 up into the selected pair of opposingnotches 62a and 62b to retain the strut 12. The bushing 40 prevents thestrut 12 from longitudinally moving relative to the wing assembly 18while the bushing 40 is within a notch.

When a finger 66 applies downward pressure on the push-button top 32,the spring 38 is compressed and pushes the connected bushing 40 down outof the opposing notches 62a and 62b. With pressure still applied, theentire wing assembly 18 can be translated up or down the slot 46 (orvice-versa) until the pressure on the button 32 is removed and thebushing (stop member) 40 re-engages one of the pair of opposing notches62a and 62b.

Figs. 5, 6 and 7 depict a second embodiment of a wing assembly,generally designated 118 that telescopes in the exact manner justdescribed with respect to the wing assembly 18. The second embodimentfunctions the same as the wing assembly 18 with respect to theadjustment of the length of the strut 12. The wing assembly 18 isprovided wit at least one strap-retaining channel 72 that runstransversely across the wing member 20. A strap-retaining loop 74extends longitudinally outward from an adjustment assembly housing 131that retains the adjustment assembly 30 across the entire width of thechannel 72 and is flush with the top of the adjustment housing 131. Theloops 74 may be formed of plastic, metal, or other suitable materialthat is resilient enough to be repeatedly bent and still spring downwardto retain the strap 54. The adjustment assembly 30 is structured andfunctions in like manner to the adjustment assembly 30. Features and/orfunctions not discussed below with respect to the wing assembly 118should be considered to be the same as those features and/or functionswith respect to the wing assembly 18 unless noted to the contrary.

This configuration gives the wing assembly 118 a lower and sleekerprofile that is less likely to get caught on obstructions during use. Inaddition, one end 78 of the retaining loop 74 is not connected to thewing body 20. The end 78 has a nub 80 to keep the strap 54 in place(Figs. 6 and 7). The end 78 may also have a snap or other positivelocking mechanism that is releasably engageable with the wing assembly118. Referring to Fig. 6, the retaining loop 74 can be pivoted or bentup at the unconnected end 78 in order easily to slip in the strap 54.When the end 78 is released, the nub 80 ensures that the strap 54 willnot slip out of the retaining channel 72. The arrow in Fig. 5 depictswhere and how another strap may be placed.

Fig. 8 depicts a third embodiment of a wing assembly, generallydesignated 218. This third embodiment telescopes in the exact mannerdescribed with respect to the wing assemblies 18 and 118. Other featuresand/or functions not discussed below with respect to the wing assembly218 should be considered to be the same as those features and/orfunctions with respect to the wing assemblies 18 and 118.

The wing assembly 218 is similar in design/appearance to the wingassembly 118. The wing assembly 218 includes a body or housing 20 havinga unitary retaining loop 74 that defines two channels 72 for receipt ofstraps (54). The adjustment assembly 230 is oval rather than round toprovide easier manipulation, and is situated at an end of the body 20,proximate the strut 12. The adjustment assembly 230 is surrounded by anadjustment housing 231.

Although the invention has been described in detail with reference to apreferred embodiment and an alternative embodiment, variations andmodifications exist within the scope and spirit of the invention.Additional features of the invention will become apparent to thoseskilled in the art upon consideration of the detailed description ofpreferred embodiments exemplifying the best mode of carrying out theinvention as presently perceived.

1. An orthopedic brace comprising: a first adjustable-length support; asecond adjustable-length support; and a hinge pivotably connecting thefirst and second supports, wherein at least one of the first and secondsupports comprises: a strut including a slot extending in a directionsubstantially parallel to a longitudinal axis of the strut; a wingmember slidable with respect to the strut; and a stop; wherein the slothas a first width in a direction perpendicular to the longitudinal axisof the strut, and a plurality of openings spaced along a center axis ofthe slot, the openings having a second width greater than the firstwidth; and the stop engages at least one opening to fix an amount ofextension of the wing member with respect to the strut.
 2. Theorthopedic brace of Claim 1, wherein the stop comprises a shaft having afirst segment with a first transverse thickness and a second segmentwith a second transverse thickness less than the first thickness.
 3. Theorthopedic brace of Claim 2, wherein the first transverse thickness isequal to or less than the second slot width and greater than the firstslot width, and the second transverse thickness is equal to or less thanthe first slot width.
 4. The orthopedic brace of Claim 3, wherein thestop is biased toward a first position in which the shaft first segmentengages one of the openings, thereby fixing an amount of extension ofthe wing member with respect to the strut.
 5. The orthopedic brace ofClaim 4, wherein the stop is slidable to a second position in which theshaft first segment disengages the openings and the first slot widthsare slidable past the shaft second segment such that the wing member isslidable with respect to the strut.
 6. The orthopedic brace of Claim 4,wherein the stop is biased by a coil spring.
 7. The orthopedic brace ofClaim 1, wherein the strut is slidable within a longitudinal channelformed in the wing member.
 8. An orthopedic brace comprising: a firstadjustable-length support; a second adjustable-length support; and ahinge pivotably connecting the first and second supports, wherein atleast one of the first and second supports comprises: a strut; a wingmember slidable with respect to the strut; and a biased stop secured tothe wing member, the stop contacting the strut to fix an amount ofextension of the wing member with respect to the strut.
 9. Theorthopedic brace of Claim 8, wherein the stop comprises a shaft.
 10. Theorthopedic brace of Claim 9, wherein the strut includes at least twoapertures spaced from one another along a longitudinal axis of thestrut.
 11. The orthopedic brace of Claim 10, wherein the stop is biasedtoward a first position in which the shaft engages one of the aperturesin the strut, thus fixing an amount of extension of the wing member withrespect to the strut.
 12. The orthopedic brace of Claim 11, wherein thestop is slidable to a second position in which the shaft disengages oneof the apertures, thus enabling the wing member to slide relative to thestrut.
 13. An orthopedic brace comprising: a first adjustable-lengthsupport; a second adjustable-length support; and a hinge pivotablyconnecting the first and second supports; wherein each of the first andsecond supports comprises a strut that is slidable within a longitudinalchannel formed in a wing member, and a stop selectively fixes a positionof the wing member with respect to the strut.
 14. The brace of Claim 13,wherein the stop comprises an actuator, a coil spring and a bushing. 15.The brace of Claim 14, wherein the actuator comprises a substantiallydisk-shaped button secured to a first end of a shaft.
 16. The brace ofClaim 15, wherein the bushing is secured to a second end of the shaft,such that the shaft is axially translatable through an aperture in thewing member, the aperture having a width less than a diameter of thebutton and less than a diameter of the bushing.
 17. The brace of Claim15, wherein the coil spring is positioned between an underside of thebutton and a surface surrounding the aperture, such that the coil springbiases the stop toward a first position.
 18. The brace of Claim 17,wherein when the stop is in the first position the bushing engages oneof a plurality of spaced notches on the strut to thereby fix a relativeposition of the wing member with respect to the strut.
 19. An orthopedicbrace, comprising: an upper support assembly including an upper strutand an upper wing member, the upper wing member including a longitudinalchannel, the longitudinal channel including a floor surface and firstand second lips spaced from the floor surface, the upper strut beingslidable within the channel to thereby adjust a position of the upperwing member with respect to the upper strut, such that a first surfaceof the upper strut contacts the floor surface and a second surface ofthe upper strut, which is opposite the first surface thereof, contactsthe first and second lips; a lower support assembly including a lowerstrut and a lower wing member, the lower wing member including alongitudinal channel, the longitudinal channel including a floor surfaceand first and second lips spaced from the floor surface, the lower strutbeing slidable within the channel to thereby adjust a position of thelower wing member with respect to the lower strut, such that a firstsurface of the lower strut contacts the floor surface and a secondsurface of the lower strut, which is opposite the first surface thereof,contacts the first and second lips; a hinge assembly rotatablyconnecting the upper and lower struts; wherein the upper wing memberincludes a first locking assembly that selectively fixes the position ofthe upper wing member with respect to the upper strut, and the lowerwing member includes a second locking assembly that selectively fixesthe position of the lower wing member with respect to the lower strut.20. The orthopedic brace of Claim 19, wherein at least a portion of eachof the upper and lower struts comprises a flat, substantiallyrectangular bar.
 21. The orthopedic brace of Claim 19, wherein each ofthe upper and lower struts includes at least one slot therein, the slotextending in the direction of a longitudinal axis of its respectivestrut.
 22. The orthopedic brace of Claim 19, wherein the hinge ismonocentric.
 23. The orthopedic brace of Claim 19, wherein the hingeincludes at least one of an extension stop for limiting an extensionrange of the brace and a flexion stop for limiting a flexion range ofthe brace.
 24. The orthopedic brace of Claim 23, wherein a position ofthe at least one of an extension stop and a flexion stop is adjustable.25. A method of treating a human leg, the method comprising the stepsof: applying to the leg an orthopedic brace, the brace comprising: anupper support assembly including an upper strut and an upper wingmember, the upper wing member including a longitudinal channel, thelongitudinal channel including a floor surface and first and second lipsspaced from the floor surface, the upper strut being slidable within thechannel to thereby adjust a position of the upper wing member withrespect to the upper strut, such that a first surface of the upper strutcontacts the floor surface and a second surface of the upper strut,which is opposite the first surface thereof, contacts the first andsecond lips; a lower support assembly including a lower strut and alower wing member, the lower wing member including a longitudinalchannel, the longitudinal channel including a floor surface and firstand second lips spaced from the floor surface, the lower strut beingslidable within the channel to thereby adjust a position of the lowerwing member with respect to the lower strut, such that a first surfaceof the lower strut contacts the floor surface and a second surface ofthe lower strut, which is opposite the first surface thereof, contactsthe first and second lips; and a hinge assembly rotatably connecting theupper and lower struts; wherein the upper support assembly includes afirst locking assembly that selectively fixes the position of the upperwing member with respect to the upper strut, and the lower supportassembly includes a second locking assembly that selectively fixes theposition of the lower wing member with respect to the lower strut;disengaging the first locking assembly, such that the upper wing memberis slidable with respect to the upper strut; adjusting a position of theupper wing member with respect to the upper strut; and engaging thefirst locking assembly, such that the upper wing member is fixed withrespect to the upper strut.
 26. The orthopedic brace of Claim 1 whereinthe slot is elongate.